Kia Sportage Workshop Manual
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Kia Sportage Workshop Manual

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Βασιλειος Παρασκευαιδης
April 25, 2025

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Summary of Contents for Kia Sportage

  • Page 1 Sportage Workshop Manual...
  • Page 2 COMPONENT...

  • Page 4: Engine Coolant Refilling And Bleeding

    ENGINE COOLANT REFILLING AND BLEEDING Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator. When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint.
  • Page 5 7. Start tart the engine and allow coolant to circula When the cooling fan operates and coolant circulates, refill coolant through the radiator cap. 8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air sufficiently out of the cooling system. 9.
  • Page 6 3. Inspect for engine coolant leaks and a drop in pressure. 4. Remove the tester and reinstall the radiator cap. Check for engine oil in the coolant and/or coolant in the engine oil.

  • Page 7: Water Pump

    REMOVAL WATER PUMP 1. Drain the engine coolant. System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool. 2. Remove the drive belts. 3.
  • Page 8 Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. 1. Drain the engine coolant so its level is below thermostat. 2. Remove the water inlet fitting(A), gasket and thermostat. RADIATOR 1. Remove the under cover(A). 2.
  • Page 9 3. Remove the air duct(A). 4. Remove the battery and tray. 5. Remove the coolant reservoir tank(A). 6. Remove the radiator upper hose(B). 7. Remove the radiator lower hose(A).
  • Page 10 8. Remove the ATF oil cooler hose(B). 9. Remove the cooling fan motor connector(A). 10. Remove the cooling fan motor assembly mounting bolt(B). 11. Remove the ATF oil cooler pipe(C). 12. Remove the cooling fan motor assembly with pulling it from the radiator. 13.
  • Page 11 14. Remove the condenser mounting bolt(A). 15. Remove the condenser bracket(B) with pulling the condenser from the radiator. 16. Remove the radiator from engine room. INSTALLATION WATER PUMP 1. Install the water pump. (1) Install the water pump(B) and a new gasket with the 3 bolts(C). Tightening torque : 11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lbf.ft)
  • Page 12 (2) Install the alternator brace(A) with the 2 bolts(D). Tightening torque : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft) 2. Install the power steering pump bracket(A) and bolts(B, C). Tightening torque : Bolts(B) : 34.3 ~ 49.0N.m (3.5 ~ 5.0kgf.m, 25.3 ~ 36.2lbf.ft) Bolts(C) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbf.ft) 3.
  • Page 13 11. Start engine and check for leaks. 12. Recheck engine coolant level. THERMOSTAT 1. Place the thermostat in thermostat housing. (1) Install the thermostat(B) with the jiggle valve upward. (2) Install a new gasket(A) to the thermostat(B). 2. Install the water inlet fitting(A). Tightening torque : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbf.ft) 3.
  • Page 14 INSPECTION WATER PUMP 1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary. 2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary. 3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly. A small amount of "weeping"...
  • Page 15 3. Check the valve lift. Valve lift : 8mm(0.3in) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat.
  • Page 16 COMPONENT...
  • Page 18 DISASSEMBLY 1. M/T : Remove the fly wheel. 2. A/T : Remove the drive plate. 3. Install the engine block onto an engine stand for disassembly. 4. Remove the timing belt. (Refer to EMA-27) 5. Remove the cylinder head. (Refer to EMA-40) 6.
  • Page 19 9. Remove the water pump. (Refer to EMA-92) 10. Remove the oil pan(A). 11. Remove the oil screen. Remove the 2bolts(C), oil screen(A) and gasket(B). 12. Check the connecting rod end play. (Refer to EMA-74, step 1) 13. Remove the connecting rod caps and check oil clearance. (Refer to EMA-74, step 2) 14.
  • Page 20 16. Remove the rear oil seal case. Remove the 5bolts(B) and rear oil seal case(A). 17. Remove the crankshaft bearing cap and check oil clearance. (Refer to EMA-76, step 4) 18. Check the crankshaft end play. (Refer to EMA-78, step 5) 19.

  • Page 21: Connecting Rod And Crankshaft

    CONNECTING ROD AND CRANKSHAFT 1. Check the connecting rod end play. Using feeler gauge, measure the end play while moving the connecting rod back and forth. End play Standard : 0.1 ~ 0.25mm (0.0039 ~ 0.0098in) Maximum : 0.4mm (0.0157in) A.If out-of-tolerance, install a new connecting rod.
  • Page 22 (8) Measure the plastigage at its widest point. Standard oil clearance 0.024 ~ 0.044mm (0.0009 ~ 0.0017in) (9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to connecting rod bearing selection table) Recheck the oil clearance.
  • Page 23 Discrimination of connecting rod Connecting rod big-end Mark inner diameter 48.000 ~ 48.006mm (1.8898 ~ 1.8900in) 48.006 ~ 48.012mm (1.8900 ~ 1.8902in) 48.012 ~ 48.018mm (1.8902 ~ 1.8905in) Crankshaft pin journal mark location Discrimination of crankshaft pin journal Mark Crankshaft pin journalouter diameter 44.960 ~ 44.966mm (1.7701 ~ 1.7703in) 44.952 ~ 44.960mm...
  • Page 24 44.946 ~ 44.952mm (1.7695 ~ 1.7698in) Connecting rod bearing mark location Discrimination of connecting rod bearing Mark Color Connecting rod bearing thickness 1.514 ~ 1.517mm Blue (0.0596 ~ 0.0597in) 1.511 ~ 1.514mm Black (0.0595 ~ 0.0596in) 1.508 ~ 1.511mm None (0.0594 ~ 0.0595in) 1.505 ~ 1.508mm Green...
  • Page 25 (White) (None) (Black) (Blue) 3. Check the connecting rods. (1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
  • Page 26 (6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to EMA-78, step 8)) Recheck the oil clearance. Do not file, shim, or scrape the bearings or the cap to adjust clearance. (7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
  • Page 27 Mark Cylinder block crankshaft journal boreinner diameter 61.000 ~ 61.006mm (2.4016 ~ 2.4018in) 61.006 ~ 61.012mm (2.4018 ~ 2.4020in) 61.012 ~ 61.018mm (2.4020 ~ 2.4023in) Crankshaft main journal mark location Discrimination of crankshaft main journal Crankshaft main journal Mark Color outer diameter 56.956 ~ 56.962mm Yellow...
  • Page 28 Crankshaft main bearing mark location Discrimination of crankshaft main bearing Mark Color Crankshaft main bearing thickness 2.014 ~ 2.017mm Blue (0.0793 ~ 0.0794in) 2.011 ~ 2.014mm Black (0.0792 ~ 0.0793in) 2.008 ~ 2.011mm None (0.0791 ~ 0.0792in) 2.005 ~ 2.008mm Green (0.0789 ~ 0.0791in) 2.002 ~ 2.005mm...
  • Page 29 5. Check the crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. End play Standard: 0.06 ~ 0.26mm (0.0024 ~ 0.0102in) Limit : 0.30mm (0.0118in) If the end play is greater than maximum, replace the thrust bearings as a set. Thrust bearing thickness : 2.44 ~ 2.77mm (0.0961 ~ 0.0972in) 6.

  • Page 30: Cylinder Block

    CYLINDER BLOCK 1. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block. 3.
  • Page 31 5. Inspect the cylinder bore diameter. Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction. Standard diameter : 82.00 ~ 82.03mm (3.2283 ~ 3.2295in) 6. Check the cylinder bore size code on the cylinder block bottom face. Discrimination of cylinder bore size Mark Cylinder bore inner diameter...
  • Page 32 7. Check the piston size mark(A) on the piston top Discrimination of piston outer diameter Mark Piston outer diameter 81.97 ~ 81.98mm (3.2272 ~ 3.2276in) 81.98 ~ 81.99mm None (3.2276 ~ 3.2279in) 81.99 ~ 82.00mm (3.2279 ~ 3.2283in) 8. Select the piston related to cylinder bore class. Piston-to-cylinder clearance : 0.02 ~ 0.04mm (0.0008 ~ 0.0016in) Boring cylinder...

  • Page 33: Piston And Piston Rings

    5. Hone the cylinders, finishing them to the proper n outside diameter + gap with cylinder). 6. Check the clearance between the piston and cylinder. Standard : 0.02 ~ 0.04mm (0.0008 ~ 0.0016in) When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.
  • Page 34 4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove. Piston ring side clearance No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in) No. 2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in) Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in) Limit No.1 : 0.1mm (0.0039in)

  • Page 35: Piston Pins

    PISTON PINS 1. Measure the outer diameter of piston pin. Piston pin diameter : 20.001 ~ 20.006mm (0.7874 ~ 0.7876in) 2. Measure the piston pin-to-piston clearance. Piston pin-to-piston clearance : 0.01 ~ 0.02mm (0.0004 ~ 0.0008in) 3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter. Piston pin-to-connecting rod interference : -0.032 ~ -0.016mm (-0.0013 ~ -0.0006in) OIL PRESSURE SWITCH...
  • Page 36 1. Check the continuity between the terminal and ohmmeter. If there is no continuity, replace the oil pressure switch. 2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed, replace the switch.
  • Page 37 1. Assemble the piston and connecting rod. (1) Use a hydraulic press for installation (2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine. 2. Install the piston rings. (1) Install the oil ring spacer and 2 side rails by hand. (2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
  • Page 38 4. Install the crankshaft main bearings. Upper 1, 2, 4, 5 bearings have an oil groove of oil holes ; Lower bearings do not. (1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A). (2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
  • Page 39 (2) Install and uniformly tighten the 10 bearing veral passes, in the sequence shown. Tightening torque : 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lbf.ft) + 60°~ 64° (3) Check that the crankshaft turns smoothly. 9. Check the crankshaft end play. (Refer to EMA-78, step 5) 10.
  • Page 40 11. Install a new gasket and rear oil seal case(A) with 5 bolts(B). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) Check that the mating surfaces are clean and dry. 12. Install the rear oil seal. (1) Apply engine oil to a new oil seal lip.
  • Page 41 13. Install the front case. (Refer to EMA-106, step 1 ~ 5) 14. Install the oil screen. Install a new gasket(B) and oil screen(A) with 2 bolts(C). Tightening torque : 14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbf.ft) 15. Install the oil pan. (1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
  • Page 42 (3) Install the oil pan(A) with the bolts. Uniformly tighten the bolts in several passes. Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 16. Install the water pump. (Refer to EMA-96) 17. Install the oil pressure switch. (1) Apply adhesive to 2 or 3 threads.
  • Page 43 18. Install the knock sensor(A). Tightening torque : 16.7 ~ 26.5N.m (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lbf.ft) 19. Install the oil level gauge tube(A). (1) Install a new O-ring on the oil level gauge tube. (2) Apply engine oil on the O-ring. (3) Install the oil level gauge tube(A) with the bolt.
  • Page 44 23. A/T : install the drive plate(A) and washer(B). Tightening torque : 117.7 ~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lbf.ft) 24. M/T : install the fly wheel. Tightening torque : 117.7 ~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lbf.ft)
  • Page 45 COMPONENT...
  • Page 47 Thank-you for purchasing this CD from Ebay user marjos42 Feel free to email me at marjose42@gmail.com...
  • Page 48 REMOVAL Engine removal is not required for this procedure. • Use Fender cover to avoid damaging painted surfaces. • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. • When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. •...
  • Page 49 3. Remove the engine cover. 4. Drain the engine coolant. (Refer to EMA-90 ) Remove the radiator cap to speed draining. 5. Remove the intake air hose and air cleaner assembly. (1) Disconnect the AFS(Air Flow Sensor) connector(A). (2) Disconnect the breather hose(B) from intake air hose. (3) Remove the intake air hose and air cleaner assembly(C).
  • Page 50 6. Remove the upper radiator hose(A) and lower r 7. Remove the heater hoses(A). 8. Remove the accelerator cable(A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
  • Page 51 9. Remove the engine wire harness connectors a lamps from cylinder head and the intake manifold. (1) Disconnect the OCV (Oil Control Valve) connector(A). (2) Disconnect the oil temperature sensor connector(B). (3) Disconnect the ECT (Engine Coolant Temperature) sensor connector(C). (4) Disconnect the ignition coil connector(D).
  • Page 52 (11) Disconnect the air conditioner compressor (E). (12) Disconnect the front heated oxygen sensor connector(A). (13) Disconnect the CKP(Crankshaft Position Sensor) connector(B). (14) Disconnect the oil pressure switch connector(C). (15) Disconnect the PCSV (Purge Control Solenoid Valve) connector(A).
  • Page 53 10. Disconnect the fuel inlet hose(A) of the deliver 11. Disconnect the hose(A) of the PCSV (Purge Control Solenoid Valve) side. 12. Remove the brake booster vacuum hose(A). 13. Remove the power steering pump drive belt. 14. Remove the power steering pump and use a wire to secure the pump to the vehicle so that it is out of the way.
  • Page 54 15. Remove the bolts(B, C) and power steering pu 16. Remove the spark plug cables. 17. Remove the exhaust manifold. (Refer to EMA-113) 18. Remove the intake manifold. (Refer to EMA-110) 19. Remove the timing belt. (Refer to EMA-27 ~ 29, step 2 ~ 15) 20.
  • Page 55 24. Remove the camshaft bearing caps(A) and camshafts(B). 25. Remove the OCV(Oil Control Valve)(A).
  • Page 56 26. Remove the OCV(Oil Control Valve) filter(A). 27. Remove the water hose(A) from water pipe(B). 28. Remove the cylinder head bolts, then remove the cylinder head. (1) Using 8mm and 10mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.

  • Page 57: Valve Guide

    (2) Lift the cylinder head from the dowels on th and replace the cylinder head on wooden blocks on a bench. Be careful not to damage the contact surfaces of the cylinder head and cylinder block. REPLACEMENT VALVE GUIDE 1. Using the SST(09221 - 3F100A), withdraw the old valve guide toward the bottom of cylinder head. 2.
  • Page 58 4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance. 5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary. VALVE GUIDE OVERSIZE Valve guide Oversize [mm Size...

  • Page 59: Installation

    1. Cut away the inner face of the valve seat to red ness. 2. Enlarge the seat ring hole of cylinder head so that matches the specified cylinder head hole inner diameter of new valve seat ring. 3. Heat the cylinder head to about 250°C(480°F) and press-fit an oversize seat ring for the cylinder head hole size. 4.
  • Page 60 1. Install the cylinder head gasket(A) on the cylind Be careful of the installation direction. 2. Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is damaged, fluid leakage could occur. 3.
  • Page 61 4. Install the OCV(Oil Control Valve) filter(A). Tightening torque : 40.2 ~ 50.0N.m (4.1 ~ 5.1kgf.m, 29.7 ~ 36.9lbf.ft) • Always use a new OCV(Oil Control Valve) filter gasket. • Keep the OCV filter clean. 5. Install the OCV(Oil Control Valve)(A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) •...
  • Page 62 6. Install the camshafts. (1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown. (2) Install the camshaft(A) and bearing caps(B). Tightening torque : 13.7 ~ 14.7N.m (1.4 ~ 1.5kgf.m, 10.1 ~ 10.8lbf.ft) (3) Install the timing chain auto tentioner(A).
  • Page 63 (4) Remove the auto tentioner stopper pin(B). 7. Check and adjust valve clearance. (Refer to EMA-14 ~ 19) 8. Using the SST (09221 - 21000), install the camshaft bearing oil seal. 9. Install the camshaft sprocket. (Refer to EMA-32, step 1) 10.
  • Page 64 • Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove. • When installing, make sure the cylinder head cover gasket is seated securely in the corners of the recesses with no gap. (2) Apply liquid gasket to the head cover gasket at the corners of the recess. •...
  • Page 65 15. Install the spark plug cables. 16. Install the power steering pump bracket(A) and bolts(B, C). Tightening torque : Bolt (B) : 34.3 ~ 49.0N.m (3.5~ 5.0kgf.m, 25.3 ~ 36.2lbf.ft) Bolt (C) : 11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lbf.ft) 17.
  • Page 66 20. Connect the hose(A) of the PCSV (Purge Con e) side. 21. Connect the fuel inlet hose(A) of the delivery pipe side. 22. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
  • Page 67 (4) Connect the oil pressure switch connector( (5) Connect the air conditioner compressor switch connector(E). (6) Connect the ground cables(D) to intake manifold. (7) Connect the knock sensor connector(C). (8) Connect the fuel injector connectors(B). (9) Connect the CMP(Camshaft position sensor) connector(A). (10) Connect the ISA(Idle Speed Actuator) connector(B).
  • Page 68 (15) Connect the OCV(Oil Control Valve) conn 23. Install the heater hose(A). 24. Install the upper radiator hose(A) and lower radiator hose(B).
  • Page 69 25. Install the intake air hose and air cleaner asse (1) Install the intake air hose, air cleaner assembly(C) and bolts. Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbf.ft) (2) Install the breather hose(B) to intake air hose. (3) Connect the AFS(Air Flow Sensor) connector(A).
  • Page 70 27. Reconnect the battery terminals(A). 28. Install the air duct(A). 29. Fill with engine coolant. 30. Start the engine and check for leaks. 31. Recheck engine coolant level and oil level. DISASSEMBLY Identify MLA(Mechanical Lash Adjuster), valves, valve springs as they are removed so that each item can be reinstalled in its original position.

  • Page 71: Cylinder Head

    2. Remove the valves. (1) Using the SST (09222 - 28000, 09222 - 28100), compress the valve spring and remove the retainer lock. (2) Remove the spring retainer. (3) Remove the valve spring. (4) Remove the valve. (5) Using a needle-nose pliers, remove the oil seal. (6) Using a magnetic finger, remove the spring seat.

  • Page 72: Valve And Valve Spring

    2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. VALVE AND VALVE SPRING 1. Inspect the valve stems and valve guides. (1) Using a caliper gauge, measure the innner diameter of valve guide. Valve guide inner diameter : 6.000 ~ 6.015mm (0.2362 ~ 0.2368in)
  • Page 73 (2) Using a micrometer, measure the outer diam Valve stem outer diameter Intake : 5.965 ~ 5.980mm (0.2348 ~ 0.2354in) Exhaust : 5.950 ~ 5.965mm (0.2343 ~ 0.2348in) (3) Subtract the valve stem outer diameter measurement from the valve guide innner diameter measurement. Valve stem- to-guide clearance Standard Intake : 0.020 ~ 0.050mm (0.0008 ~ 0.0020in)
  • Page 74 (4) Check the surface of valve stem tip for wear. If the valve stem tip is worn, replace the valve. 3. Inspect the valve seats. (1) Check the valve seat for evidence of overheating and improper contact with the valve face. Replace the seat if necessary.
  • Page 75 4. Inspect the valve springs. (1) Using a steel square, measure the out-of-square of valve spring. (2) Using vernier calipers, measure the free length of valve spring. Valve spring Standard Free height : 48.86mm (1.9236in) Load : 18.8±0.9kg/39.0mm (41.4±2.0lb/1.5354in) 41.0±1.5kg/30.5mm (90.4±3.3lb/1.2008in) Out of square : Less than 1.5°...
  • Page 76 If the cam lobe height is less than minimum, re 2. Inspect the camshaft journal clearance. (1) Clean the bearing caps and camshaft journals. (2) Place the camshafts on the cylinder head. (3) Lay a strip of plastigage across each of the camshaft journal. (4) Install the bearing caps and tighten the bolts with specified torque.
  • Page 77 3. Inspect the camshaft end play. (1) Install the camshafts. (Refer to EMA-55, step 6) (2) Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in) If the end play is greater than maximum, replace the camshaft.
  • Page 78 (4) With low air pressure applied, turn the CVV E direction as indicated in the illustration. A.With the low air pressure applied, the CVVT should turn to the ADVANCE side. B.If too much air leaks when applying the low air pressure, the CVVT lock pin may not release and the CVVT may not turn.
  • Page 79 (3) Install the valve, valve spring and spring retainer. Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer. (4) Using the SST(09222 - 28000, 09222 - 28100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
  • Page 80 2. Install the MLA(Mechanical Lash Adjuster)s. Check that the MLA rotates smoothly by hand.
  • Page 81 REMOVAL • Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion. • Mark all wiring and hoses to avoid misconnection. 1. Remove the air duct(A). 2. Disconnect the battery terminals(A) and remove the battery.
  • Page 82 3. Remove the engine cover. 4. Drain the engine coolant. (Refer to EMA-90) Remove the radiator cap to speed draining. 5. Remove the intake air hose and air cleaner assembly. (1) Disconnect the AFS(Air Flow Sensor) connector(A). (2) Disconnect the breather hose(B) from intake air hose. (3) Remove the intake air hose and air cleaner assembly(C).
  • Page 83 7. Remove the heater hose(A). 8. Remove the accelerator cable(A). 9. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold. (1) Disconnect the OCV(Oil Control Valve) connector(A). (2) Disconnect the oil temperature sensor connector(B). (3) Disconnect the ECT(Engine Coolant Temperature) sensor connector(C).
  • Page 84 (6) Disconnect the ISA(Idle Speed Actuator) co (7) Disconnect the CMP(Camshaft Position Sensor) connector(A). (8) Disconnect the four fuel injector connectors(B). (9) Disconnect the knock sensor connector(C). (10) Disconnect the ground cables(D) from the intake manifold and vehicle's body. (11) Disconnect the air conditioner compressor switch(E). (12) Disconnect the front heated oxygen sensor connector(A).
  • Page 85 (15) Disconnect the PCSV (Purge Control Sole ector(A). 10. Disconnect the fuel inlet hose(A) of the delivery pipe side. 11. Disconnect the hose(A) of the PCSV (Purge Control Solenoid Valve) side.
  • Page 86 12. Remove the brake booster vacuum hose(A). 13. Remove the power steering oil hose(A) from the power steering pump. 14. Remove the power steering lower oil hose(A).
  • Page 87 15. Remove the battery tray bracket. 16. Remove the transaxle wire harness connectors and control cable from transaxle(A/T). (1) Disconnect the solenoid valve connector(A). (2) Disconnect the transaxle range switch connector(B). (3) Disconnect the input shaft speed sensor connector(C). (4) Disconnect the output shaft speed sensor connector(A).
  • Page 88 (5) Disconnect the vehicle speed sensor conn (6) Remove the control cable(A). 17. Remove the transaxle oil cooler hose(A) (A/T).
  • Page 89 18. Remove the under cover(A). 19. Remove the front exhaust pipe(A). 20. Disconnect the ABS wheel speed sensor(A) from both front knuckle. (See DS group - front axle)
  • Page 90 21. Remove the front strut lower mounting bolts a (See SS griup - front strut) 22. Remove the caliper and hang the caliper assembly(A). 23. Remove the steering u-joint mounting bolt(A). (See ST group - steering) 24. Install the jack for supporting engine and transaxle assembly.
  • Page 91 25. Remove the engine mounting bracket(A). Tightening torque Nut(D) : 58.8 ~ 78.5N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9lbf.ft) Bolt(B), Nut(C) : 49.0 ~ 63.7N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0lbf.ft) 26. Remove the transaxle mounting bracket(A). Tightening torque Bolt(B) : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.61lbf.ft) 27.

  • Page 92: Installation

    28. Remove the engine and transaxle assembly by lifting vehicle. When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components. INSTALLATION Installation is in the reverse order of removal. Perform the following : •...
  • Page 93 • Refill the engine with engine oil. • Refill the transaxle with fluid. • Refill the radiator and reservoir tank with engine coolant. • Place the heater control knob on "HOT" positon. • Bleed air from the cooling system - Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) - Turn Off the engine.
  • Page 94 COMPONENT...

  • Page 95: Compression Pressure Inspection

    COMPRESSION PRESSURE INSPECTION If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Start the engine and allow to warm up to operating temperature (about five minutes). Stop the engine. 2. Disconnect the ignition coil connectors and the spark plug cables. 3.

  • Page 96: Timing Belt Tension Adjustment

    Compression pressure : 1,422kPa (14.5kg/cm², 206psi) (250~400 rpm) Minimum pressure : 1,275kPa (13.0kg/cm², 185psi) Difference between each cylinder : 98kPa (1.0kg/cm², 14psi) or less (5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step (1) through (3) for cylinders with low compression.
  • Page 97 4. Loosen the water pump pulley bolts. 5. Remove the alternator drive belt. (See EE group - alternator) 6. Remove the air conditioner compressor drive belt. (See HA group - air conditioner compressor) 7. Remove the power steering pump drive belt. (See ST group - power steering pump) 8.
  • Page 98 11. Remove the crankshaft pulley bolt(B) and crankshaft pulley(A). 12. Remove the 5 bolts(B) and timing belt lower cover(A). 13. Temporarily loosen the tensioner pulley(A) by center bolt.
  • Page 99 14. Adjust the timing belt tension. (1) Rotate the crankshaft clockwise (view from the front) through angle equivalent to two teeth (18°)of camshaft sprocket(A). (2) Using a hex-wrench, apply tension to the timing belt in the clockwise direction so that there is no slack in the belt on the tension side.
  • Page 100 (4) Recheck the belt tension. When applying about elt should move no more than 0.16 to 0.24 inch (4 to 6 mm). 15. Turn the crankshaft two turns in the operating direction (clockwise) and realign the crankshaft sprocket and camshaft sprocket timing mark.
  • Page 101 18. Install the timing belt upper cover(A) with bolts(B). Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbf.ft) 19. Install the water pump pulley. 20. Install the power steering pump drive belt. (See ST group - power steering pump) 21.
  • Page 102 25. Install the engine cover(A) with bolts. Tightening torque : 3.9 ~ 5.9N.m ( 0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lbf.ft) VALVE CLEARANCE INSPECTION AND ADJUSTMENT MLA(MECHNICAL LASH ADJUSTER) Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : (20°C ± 5°C [68°F ± 9°F]) and cylinder head is installed on cylinder block.
  • Page 103 3. Remove the cylinder head cover. (1) Disconnect the spark plug cables and do not pull on the cable by force. Pulling on or bending the cables may damage the conductor inside. (2) Remove the PCV (Positive Crankcase Ventilation) hose(A) and the breather hose(B) from the cylinder head cover. (3) Remove the accelerator cable(A) from the cylinder head cover.
  • Page 104 (4) Loosen the cylinder head cover bolts(B) and then A) and gasket. 4. Set No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing belt cover. (2) Check that the hole of the camshaft timing pulley(A) is aligned with the timing mark of the bearing cap. If not, turn the crankshaft one revolution (360°).
  • Page 105 5. Inspect the valve clearance. (1) Check only the valve indicated as shown. [No. 1 cylinder : TDC/compression]. Measure the valve clearance. A.Using a thickness gauge, measure the clearance between the tappet shim and the base circle of camshaft. B.Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
  • Page 106 6. Adjust the intake and exhaust valve clearance. (1) Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve is upward. (2) Using the SST(09220 - 2D000), press down the valve lifter and place the stopper between the camshaft and valve lifter and remove the special tool.
  • Page 107 (6) Select a new shim with a thickness as close as p ated value. (Refer to the Adjusting shim selection chart) Shims are available in 20 size increments of 0.04mm (0.0016in) from 2.00mm (0.0787in) to 2.76mm (0.1087in) (7) Place a new adjusting shim on the valve lifter. (8) Using the SST(09220 - 2D000), press down the valve lifter and remove the stopper.

  • Page 110: Special Service Tools

    SPECIAL SERVICE TOOLS Tool (Number and name) Illustration Crankshaft front oil seal Installation of the front oil seal installer (09214-32000) Crankshaft front oil seal Installation of the front oil seal guide (09214-32100) Valve clearance adjust Removal and installation of the tappet shim tool set (09220-2D000) Camshaft oil seal installer...
  • Page 111 Valve stem oil seal installer Installation of the valve stem oil seal (09222-22001) Valve spring compressor Removal and installation of the intake or (09222-28000) exhaust valve Valve spring compressor adaptor (09222-28100) Crankshaft rear oil seal Installation of the crankshaft rear oil seal installer (09231-21000)

  • Page 112: Specifications

    GENERAL SPECIFICATIONS Description Specifications (2.0 DOHC) Limit General Type In-line, DOHC Number of cylinders Bore 82mm (3.2283in) Stroke 93.5mm (3.6811in) Total displacement 1,975 cc (120.5 cu.in) Compression ratio 10.1 : 1 Firing order 1-3-4-2 Valve timing Opens (ATDC) 11° Intake valve Closes (ABDC) 59°...
  • Page 113 ring 33.300 ~ 33.325mm (1.3110 ~ 0.3 OS hole diameter 1.3120in) 33.600 ~ 33.625mm (1.3228 ~ 0.6 OS 1.3238in) 28.500 ~ 28.521mm (1.1220 ~ 1.1229in) Exhaust valve seat 28.800 ~ 28.821mm (1.1339 ~ ring 0.3 OS 1.1347in) hole diameter 29.100 ~ 29.121mm (1.1457 ~ 0.6 OS 1.1465in) Camshaft...
  • Page 114 0.020 ~ 0.050mm (0.0008 ~ Intake 0.10mm (0.0039in) Valve stem to 0.0020in) Valve guide 0.035 ~ 0.065mm (0.0014 ~ clearance Exhaust 0.13mm (0.0051in) 0.0026in) Valve guide Intake 45.8 ~ 46.2mm (1.8031 ~ 1.8189in) Length Exhaust 54.3 ~ 54.6mm (2.1378 ~ 2.1496in) Valve seat Intake 1.1 ~ 1.5mm (0.0433 ~ 0.0591in)
  • Page 115 0.020 ~ 0.040mm (0.0008 ~ Piston to cylinder clearance 0.0016in) No. 1 ring groove 1.23 ~ 1.25mm (0.0484 ~ 0.0492in) Ring groove width No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in) Oil ring groove 2.51 ~ 2.53mm (0.0988 ~ 0.0996in) Piston ring No.
  • Page 116 44.946 ~ 44.966mm (1.7695 ~ Pin journal outer diameter 1.7703in) 0.028 ~ 0.048mm (0.0011 ~ Main bearing oil clearance 0.1mm (0.0039in) 0.0019in) End play 0.06 ~ 0.260mm (0.0024 ~ 0.0102in) 0.3mm (0.0118in) Flywheel Runout 0.1mm (0.0039in) 0.13mm (0.0051in) Oil pump 0.040 ~ 0.085mm (0.0016 ~ Inner rotor 0.0033in)

  • Page 117: Tightening Torque

    93.16 ~ 122.58kpa Main valve opening (0.95 ~ 1.25kg/cm², 13.51 ~ pressure 17.78psi) Radiator cap Vacuum valve opening 0.98 ~ 4.90 kpa pressure (0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi) Water temperature sensor Type Thermister type 20°C (68°F) 2.45±0.14 kΩ Resistance 80°C (176°F) 0.3222 kΩ...
  • Page 118 Rear roll stopper insulator and rear roll stopper 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0 support bracket fixing bolt,nut Main moving system Connecting rod cap nut 49.0 ~52.0 5.0 ~5.3 36.2 ~38.3 27.5~31.4+60° 2.8~3.2+60° 20.3~23.1+60° Crankshaft main bearing cap bolt ~64° ~64°...
  • Page 119 Water pump bolt (8 X 35) 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8 Water pump and alternator brace fixing bolt (8 X 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Alternator brace and cylinder block fixing bolt 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8...
  • Page 120 Exhaust manifold and front muffler fixing bolt 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4 Front muffler fixing clip bolt 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9 Front muffler and center muffler fixing nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4 Center muffler and main muffler fixing nut...

  • Page 121: Troubleshooting

    TROUBLESHOOTING Symptom Suspect area Remedy Engine misfire with Repair or replace the flywheel as Loose or improperly installed engine flywheel. abnormal internal required. lower engine noises. Worn piston rings. Inspect the cylinder for a loss of (Oil consumption may or may not cause the compression.
  • Page 122 Stretched or broken timing chain and/or damaged Replace the timing chain and sprocket teeth. sprockets. Replace the timing chain tensioner as Worn timing chain tensioner, if applicable. required. Worn camshaft lobes. Inspect the camshaft lobes. Replace the camshaft and valve lifters as required.
  • Page 123 Engine noise under Low oil pressure. Repair or replace as required. load. Excessive connecting rod bearing clearance. Inspect the following components and repair as required. • The connecting rod bearings. • The connecting rods. • The crankshaft. Excessive crankshaft bearing clearance. Inspect the following components and repair as required.
  • Page 124 COMPONENT...
  • Page 125 Thank-you for purchasing this CD from Ebay user marjos42 Feel free to email me at marjose42@gmail.com...
  • Page 126 REMOVAL 1. Remove the engine cover. 2. Disconnect the front oxygen sensor connector. 3. Remove the front muffler(A). Tightening torque : Nut (B) : 39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lbf.ft) Bolt (C) : 29.4 ~ 39.2N.m (3.0 ~ 4.0kgf.m, 21.7 ~ 28.9lbf.ft) 4.
  • Page 127 5. Remove the exhaust manifold and catalytic converter assembly. Tightening torque : 42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lbf.ft) 6. Installation is in the reverse order of removal...
  • Page 128 COMPONENT...
  • Page 130 IDENTIFICATION NUMBER LOCATIONS...
  • Page 131 1 - 3 : Make / Vehicle type - KND = Kia MPV 4 - 5 : Vehicle Line /Series - JE = SPORTAGE 4x4 - JF = SPORTAGE 4x2 6 - 7: Body type - 72 = 4Door Sport Utility Vehicle & GVW 1821 ~ 2270kg 8 : Engine type - 2 = 2.0 Gasoline (G4GC) (Federal)

  • Page 132: Engine Identification Number

    12 - 17 : Sequential number - 000001 ~ 999999 PAINT CODE CODE COLOR Clear White Grayish Silver Satin Silver Greenish Gold Natural Oliv Vert Jade Pearl Smart Blue Volcanic Red Smokey Brown Black Cherry ENGINE IDENTIFICATION NUMBER 1. Engine fuel - G : Gasoline 2.
  • Page 133 3. Engine development order - B : DELTA Engine - G : BETA Engine 4. Engine capacity - A : 2656cc (Gosoline) - C : 1975 cc (Gasoline) 5. Production year - 4 : 2004, 5 : 2005, 6 : 2006 6.

  • Page 134: Warning / Caution Label Locations

    1. Modle - N : F4A42-2 2. Production year - 4 : 2004, 5 : 2005, 6 : 2006, 7 : 2007 3. Gear ratio - N : 4.042 - O : 4.407 - R : 4.626 4. Detailed chassification - AD : 2.0 2WD - BD : 2.0 4WD - FD : 2.7 4WD...
  • Page 135 AIR BAG WARNING / CAUTION LABEL...
  • Page 137 AIR BAG WARING / CAUTION LABEL (CONT'D)
  • Page 138 WARNING / CAUTION LABEL (cont'd) A : WARNING SEE OWNER'S MANUAL. This car is equipped a side airbag for each front seat. • Do not use any accessory seat covers. • Use of other seat covers could reduce the effect of the system. •...
  • Page 139 D : SUPPLEMENTAL RESTRAINT SYSTEM (AIRBAG) INFOR • The airbag is a Supplement Restraint System (SRS). You must always wear the seat belts. • The airbag system condition is normal when the "SRS" lamp in the cluster flashes approximately 6 times after the ignition key is turned on and then goes off.

  • Page 140: Lift And Support Points

    LIFT AND SUPPORT POINTS When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of the vehicle, the center of gravity may change and cam cause the vehicle to tip forward on the hoist.
  • Page 141 1. Place the lift blocks under the support points as shown in the il 2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported. 3. Raise the hoist to full height to inspect the lift points for secure support.
  • Page 142 Fuel tank cauld be damaged or broken when using the lift in the illustration above. So, install the rubber or wooden block on the position supporting the lift and then lift up the vehicle. Minimum height of the block is 8cm. TOWING If the vehicle needs to be towed, call a professional towing service.
  • Page 143 • Release the parking brake. • Shift the transmission to neutral Automatic Transmission • Release the parking brake. • Start the engine. • Shift to [D] position, then [N] position. • Turn off the engine. • Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine(automatic transmission), your vehicle must be transported on a flatbed.
  • Page 144 TIGHTENING TORQUE TABLE OF STANDARD PARTS Torque Nm (kg.cm, lb.ft) Bolt nominal diameter (mm) Pitch (mm) Head Mark 4 Head Mark 7 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)
  • Page 145 ~ 6 (50 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0) 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0 ) 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36) 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33)
  • Page 146 Transaxle linkage, parking breake cable mechanism, hood, door latch, Multipurpose grease NIGL grade #2 seat adjuster, tailgate latch, door hinges, tailgate hinge Always use Genuine Kia motors parts and recommedended fluid. Using any other type of parts and fluid can cause serious damage to vehicle. LUBRICANTS CAPACITIES...
  • Page 147 Automatic transaxle , 6.8) 7.8 (8.2, 6.8) Power steering 0.9 (0.95, 0.79) 0.9 (0.95, 0.79) Capacities : [liter (U.S.qts, Imp.qts)] SELECTION OF ENGINE OIL (Gasoline) RECOMMENDED ILSAC classification : GF-3 OR ABOVE RECOMMENDED API classification : SL(SJ) OR ABOVE RECOMMENDED SAE viscosity grades :...

  • Page 148: General Service Information

    For best performance and maximum protection of all types of operation, select only those lubricants which : 1.Satisfy the requirements of the API classification. 2.Have the proper SAE grade number for expected ambient temperature range. 3.Lubricants that do not have both an SAE grade number and API service classification on the container should not be used. GENERAL SERVICE INFORMATION PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas before starting work.

  • Page 149: Removal Of Parts

    REMOVAL OF PARTS First find the cause of the problem and then determine whether removal or disassembly before starting the job. DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not aggect their performance or external appearance.
  • Page 150 1.Inspection of parts Each part, when removed, should be carefulley on spected for malfunction, deformation, damage, and other problems. 2.Arrangement of parts All disassembled parts should be carefully arranged for effective reassembly. Be sure to separate and correctly identify the parts to be repllaced from those that will be used again.
  • Page 151 3.Cleaning parts for reuse All parts to be used again should be carefully and thoroughly cleaned by an appropriate method. PARTS When replacing parts, use KIA MOTORS genuine parts.
  • Page 152 REPLACEMENT Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, the following parts should always be replaced with new ones. 1.Oil seals 2.Gaskets 3.O-rings 4.Lock washers 5.Cotter pins (split pins)
  • Page 153 6.Plastic nuts Depending on their location. 7.Selalant should be applied to gaskets. 8.Oil should be applied to the moving components of parts. 9.Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly. ADJUSTMENT...

  • Page 154: Electrical System

    Use gauges and testers to adjust correclty the parts to standard ELECTRICAL SYSTEM 1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery. 2. Never pull on the wires when disconnecting connectors. 3. Locking connectors will click when the connector is secure. 4.
  • Page 155 MEASURING BODY DIMENSIONGS 1. Basically, all measurements in this manual are taken with a tracking gauge. 2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. 3. For measuring dimensions, both projected dimensioners and actual - measurement dimensions are used in this manual. DIMENSIONS PROJECTED 1.
  • Page 156 MEASURING ACTUAL DIMENSIONS 1. These dimensions indicate the actual linear distance between mesaurement points, and are used as the reference dimensions when a tracking gauge is used for measurement. 2. First adjust both probes to the same length (A=A') before measurement. Check the probes and gauge itself to make sure there is no free play.

  • Page 157: Measurement Point

    MEASUREMENT POINT Measurements should be taken at the center fo the hole. CHECKING CABLES AND WIRES 1. Check the terminal for tightness. 2. Check terminals and wires for corrosion from battery electrolyte, etc. 3. Check terminals and wires for open corcuits.

  • Page 158: Check Fuses

    4. Check wire insulation and coating for damage, cracks and deg 5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounded parts to verify that there is complete continuity between thier attaching bolt(s) and the vehicle's body. 7.
  • Page 159 SERIVICING THE ELECTRICAL SYSTEM 1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable. In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by the computer will be cleared.
  • Page 160 2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact with any of the surronding parts and then secure the harness by using a clamp.
  • Page 161 4. When installing any parts, be careful not to pinch or damage any of the wiring harness. 5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
  • Page 162 6. The electronlic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand. 7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
  • Page 163 8. When disconnecting a connector, be sure to grip only the connector, not the wires. 9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
  • Page 164 10. Connect connectors which have catches by inserting the connectors until they make a clicking sound. 11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the terminal, being careful not to damage the insulation of the wires.

  • Page 165: Precautions For Catalytic Converter

    12. To avoid overloading the wiring, take the electrical current loa quipment into consideration, and determine the appropartate wire size. Permissible current Noeminal size SAE gauge No. In engine compartment Other areas 0.3mm² AWG 22 0.5mm² AWG 20 0.85mm² AWG 18 1.25mm²...
  • Page 167 MAINTENANCE SCHEDULE SCHEDULE 1 - NORMAL MAINTENANCE...
  • Page 168 SCHEDULE 2 - SEVERE MAINTENANCE...
  • Page 170 COMPONENT...
  • Page 171 REMOVAL 1. Remove the engine cover. 2. Disconnect the TPS(Throttle Position Sensor) connector(A) and ISA(Idle Speed Actuator) connector(B). 3. Disconnect the PCV(Positive Crankcase Ventilation) hose(A) and breather hose(B). 4. Remove the accelerator cable.
  • Page 172 5. Remove the delivery pipe(A). Tightening torque : 18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lbf.ft) 6. Remove the heater hose(A), PCSV(Purge Control Solenoid Valve)(B) and the brake vacuum hose(C) from throttle body and intake manifold. 7. Remove the air conditioner compressor. (Refer to HA Gr.) 8.
  • Page 173 9. Remove the intake manifold. Tightening torque : 15.7 ~ 22.6N-m (1.6 ~ 2.3kg-m, 11.6 ~ 16.6lb-ft) 10. Installation is in the reverse order of removal with new gasket.
  • Page 174 Thank-you for purchasing this CD from Ebay user marjos42 Feel free to email me at marjose42@gmail.com...
  • Page 175 COMPONENT...

  • Page 177: Oil And Filter Replacement

    OIL AND FILTER REPLACEMENT • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.

  • Page 178: Selection Of Engine Oil

    2. Check the engine oil level. After warming up the engine for five minutes, stop the engine and check the oil leverl. The level should be between the "L" and "F" marks on the dipstick. If low, check for oil leakage and add oil up to the "F" mark on the dipstick. Do not fill with engine oil above the "F"...
  • Page 179 For best performance and maximum protection of all types of operation, select only those lubricants which : 1.Satisfy the requirement of the API classification. 2.Have proper SAE grade number for expected ambient temperature range. 3.Lubricants that do not have both an SAE grade number and API service classification on the container should not be used.
  • Page 180 REMOVAL OIL PAN 1. Drain the engine oil. 2. Disconnect the rear oxygen sensor connector. 3. Remove the front muffler(A). 4. Remove the exhaust manifold. (Refer to EMA-113) 5. Remove the front muffler bracket(A). 6. Remove the oil pan.

  • Page 181: Oil Pump

    OIL PUMP 1. Drain the engine oil. 2. Remove the drive belts. 3. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. 4. Remove the timing belt. (Refer to EMA-27) 5. Remove the bolt(B) and timing belt idler(A). 6.

  • Page 182: Installation

    (1) Remove the screw(B) from the pump housin the housing and cover(A). (2) Remove the inner rotor(A) and outer rotor(B). INSTALLATION OIL PUMP 1. Install the oil pump. (1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side. (2) Install the oil pump cover(A) to front case with the 7 screws(B).
  • Page 183 2. Check that the oil pump turns freely. 3. Install the oil pump on the cylinder block. (1) Place a new front case gasket on the cylinder block. (2) Apply engine oil to the lip of the oil pump seal. Then, install the oil pump onto the crankshaft. (3) When the pump is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.
  • Page 184 5. Using the SST(09214-32000), install the front c 6. Install the air conditioner compressor tensioner bracket (A). 7. Install the alternator. (See EE group - alternator) 8. Install the oil screen. Tightening torque : 14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbf.ft) 9.
  • Page 185 13. Fill with engine oil. OIL PAN 1. Install the oil pan. (1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces. Check that the mating surfaces are clean and dry before applying liquid gasket. (2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
  • Page 186 2. Install the front muffler bracket(A). 3. Install the exhaust manifold. (Refer to EMA-113) 4. Install the front muffler(A). 5. Connect the rear oxygen sensor connector. 6. Fill with engine oil DISASSEMBLY RELIEF PLUNGER 1. Remove the relief plunger. Remove the plug(A), spring(B) and relief plunger(C).
  • Page 187 INSPECTION 1. Inspect the relief plunger. Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight. If it does not, replace the relief plunger. If necessary, replace the front case. 2.
  • Page 188 If the tip clearance is greater than maximum, replace the rotors as a set. 5. Inspect the rotor body clearance. Using a feeler gauge, measure the clearance between the outer rotor and body. Body clearance 0.120 ~ 0.185mm (0.0047 ~ 0.0073in) If the body clearance is greater than maximum, replace the rotors as a set.
  • Page 190 COMPONENT...
  • Page 191 REMOVAL Engine removal is not required for this procedure. 1. Remove the engine cover. 2. Remove the RH front wheel. 3. Remove the 2 bolts(B) and RH side cover(A). 4. Remove the engine mounting support bracket. (1) Set the jack to the engine oil pan.
  • Page 192 (2) Remove the bolt(B), nuts(C,D) and engine bracket(A). (3) Remove the bolt(B) and engine support bracket stay plate(A). 5. Temporarily loosen the water pump pulley bolts. 6. Remove the alternator drive belt. (See EE group - alternator) 7. Remove the air conditioner compressor drive belt. (See HA group - air conditioner compressor) 8.
  • Page 193 10. Remove the 4 bolts(B) and timing belt upper c 11. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. Check that the timing mark of camshaft sprocket is aligned with the timing mark of cylinder head cover. (No.1 cylinder compression TDC position)
  • Page 194 12. Remove the crankshaft pulley bolt(B) and cran 13. Remove the crankshaft flange(A). 14. Remove the 5 bolts(B) and timing belt lower cover(A)
  • Page 195 15. Remove the timing belt tensioner(A) and timin If the timing belt is going to be reused, make an arrow indicating the turning direction to make sure that the belt is reinstalled in the same direction as before. 16. Remove the bolt(B) and timing belt idler(A).
  • Page 196 17. Remove the crankshaft sprocket(A). 18. Remove the cylinder head cover. (1) Disconnect the spark plug cables and do not pull on the cable by force. Pulling on or bending the cables may damage the conductor inside. (2) Remove the PCV (Positive Crankcase Ventilation) hose(A) and the breather hose(B) from the cylinder head cover.
  • Page 197 (3) Remove the accelerator cable(A) from the (4) Loosen the cylinder head cover bolts(B) and then remove the cover(A) and gasket. 19. Remove the camshaft sprocket. (1) Hold the portion(A) of the camshaft with a hexagonal wrench, and remove the bolt(C) with a wrench(B) and remove the camshaft sprocket.
  • Page 198 1. Install the camshaft sprocket and tighten the bo torque. (1) Temporarily install the camshaft sprocket bolt(C). (2) Hold the portion(A) of the camshaft with a hexagonal wrench, and tighten the bolt(C) with a wrench(B) . Tightening torque : 98.1 ~ 117.7N.m (10 ~ 12kgf.m, 72.3 ~ 86.8lbf.ft) 2.
  • Page 199 (2) Install the PCV(Positive Crankcase Ventilati breather hose(B) to the cylinder head cover. (3) Install the accelerator cable(A) to the cylinder head cover. (4) Install the spark plug cables.
  • Page 200 3. Install the crankshaft sprocket(A). 4. Align the timing marks of the camshaft sprocket(A) and crankshaft sprocket(B) with the No. 1 piston placed at top dead center and its compression stroke.
  • Page 201 5. Install the idler pulley(A) and tighten the bolt(B) orque. Tightening torque : 42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lbf.ft) 6. Temporarily install the timing belt tensioner(A) with plain washer(B). 7. Install the belt so as not give slack at each center of shaft. Do as following procedures when installing timing belt. Crankshaft sprocket(A) idler pulley(B) camshaft sprocket(C)
  • Page 202 8. Temporarily install tensioner pulley using cente on force to the belt. 9. Adjust the timing belt tension. (1) Rotate the crankshaft clockwise(view from front) through angle equivalent to two teeth(18°) of camshaft sprocket(A). (2) Using a hex-wrench, apply tension to the timing belt in the clockwise direction so that there is no slack in the belt on the tension side.
  • Page 203 10. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark. 11. Install the timing belt lower cover(A) with 5bolts(B). Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbf.ft) 12.
  • Page 204 13. Install the timing belt upper cover(A) with 4 bolts(B). Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbf.ft) 14. Install the water pump pulley and 4 bolts. 15. Install the power steering pump drive belt. (See ST group - power steering pump) 16.
  • Page 205 (2) Install the engine mounting support bracket(A) with nuts(C,D) and bolt(B). Tightening torque : Nut(D) : 58.8 ~ 78.5N.m (6.0 ~ 8.0kgf.m, 43.4 ~ 57.9lbf.ft) Nut(C) and bolt(B) : 49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbf.ft) 20. Install the RH side cover(A) with 2 bolts(B).

  • Page 206: Timing Belt

    21. Install the RH front wheel. Tightening torque : 88.3 ~ 98.N.m (9.0 ~ 10.0kgf.m, 65.1 ~ 72.3lbf.ft) 22. Install the engine cover with bolts. Tightening torque : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lbf.ft) INSPECTION SPROCKETS, TENSIONER, IDLER 1.
  • Page 207 2. When the engine is overhauled or belt tension he carefully. If any damage is found, replace the belt. • Do not bend, twist or turn the timing belt inside out. • Do not allow timing belt to come into contact with oil, water and steam.

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